(per)fluoropolyether block copolymers

ABSTRACT

The invention relates to (per)fluoropolyether block copolymers comprising: A) a fluoropolyoxyalkylene segment (chain R a ) comprising one or more units of formula (CHXCF 2 CF 2 O)— in which X is hydrogen or fluorine; B) a (per)fluoropolyoxyalkylene segment (chain Rf), that is to say a segment comprising recurring units having at least one catenary ether bond and at least one fluorocarbon moiety, said (per)fluoropolyoxyalkylene segment being different from chain R a  and having a molecular weight higher than 400 g/mol. These copolymers are endowed with improves lubricant properties or with improved water and oil-repellence properties.

This application is a U.S. national stage entry under 35 U.S.C. §371 of International Application No. PCT/EP2012/061782 filed Jun. 20, 2012, which claims priority to European Application No. 11171363.2, filed on Jun. 24, 2011. The entire contents of these applications are explicitly incorporated herein by this reference.

TECHNICAL FIELD

The present invention relates to (per)fluoropolyether (PFPE) block copolymers, in particular to (per)fluoropolyether block copolymers containing segments that can be obtained by ring-opening reaction of 2,2,3,3-tetrafluorooxethane with a (per)fluoropolyether.

BACKGROUND ART

EP 0148482 A (DAIKIN IND LTD) relates to halogen-containing PFPEs which are said to be suitable for a variety of uses, e.g. lubricants. This document discloses, inter alia, a halogen-containing PFPE having formula [formula (XII) on page 5, lines 18-26]: A(CH₂CF₂CF₂O)_(p)[CF(CF₃)CF₂O]_(q)CF(CF₃)COF wherein: p is an integer of 2 to 200 and q is an integer of 0 to 50 and A is F, Br, I or it can be a group of formula: R_(f)CF₂O— or a group of formula: R_(f)′O—(CF(CF₃)CF₂O)_(p+1) in which R_(f) and R′_(f) can represent a perfluoroalkyl group having from 1 to 10 carbon atoms and p is an integer of 0 to 50 [formulae (VIII) and (IX) on page 4, lines 19-22].

U.S. Pat. No. 4,904,417 (DAIKIN IND LTD) discloses the reaction of compounds of formula A-(CF₂CF₂)_(m)-A′, wherein m is an integer from 1 to 6 and A and A′ are, possibly, COF, with 2,2,3,3-tetrafluorooxethane in the presence of fluoride anions as polymerization initiators, to yield derivatives having COF end groups.

U.S. Pat. No. 6,136,331 (DAIKIN IND LTD) U.S. Pat. No. 6,136,331 to Daikin discloses cosmetic compositions comprising compounds of formula XO—[CF(CF₃)₂O]_(h)(CF₂CF₂O)_(o)—Y—COOR₃, wherein h+o ranges from 1 to 100, X can be H, F, Cl, Br, or at least partially fluorinated alkyl group, Y is a partially or completely fluorinated alkyl group, and R³ is a C₁-C₂₂ aliphatic group. These compounds can be notably manufactured by reaction of a hexafluoropropylene oxide oligomer having acyl fluoride end groups and 2,2,3,3-tetrafluorooxethane in the presence of a catalyst, and subsequent reaction of the compound obtained therefrom to derivatize the COF end group with an alcohol compound or by fluorination. The catalyst can be notably KF, CsF. Preparative example 5 discloses, for instance, the reaction of a HFPO dimer [C₃F₇O—CF(CF₃)FCOF] with 2,2,3,3-tetrafluorooxethane and CsF and subsequent reaction with methanol to yield a compound of formula: C3F₇OC(CF₃)FCF₂O—(CH₂CF₂ CF₂O)_(n)—CH₂CF₂—COOCH₃ with n˜10.

JP 2003231719 (DAIKIN IND LTD) discloses certain fluoroelastomers comprising recurring units derived from particular vinyl ether compounds; among the synthetic methods used in the exemplified working embodiments of this application for manufacturing said recurring units, use is made of the reaction of 2,2,3,3-tetrafluorooxethane to provide acyl fluoride compounds, more precisely I—CH₂CF₂—COF and Cl—CH₂CF₂—COF.

US 2006281946 (DAIKIN IND LTD) describes the synthesis of compounds of formula: Rf₁—(OCH₂CF₂CF₂)_(n1)OCX₁X₂CF₂(Rf₂)_(n2)—COOM wherein Rf¹ is a straight or branched fluoroalkyl group containing 1 to 20 carbon atoms, optionally containing 1 to 5 oxygen atoms in the main chain, by ring-opening polymerization reaction of an acyl fluoride derivative of formula Rf₃—COF with 2,2,3,3-tetrafluorooxethane, wherein Rf₃ is a straight or branched fluoroalkyl group containing 1 to 20 carbon atoms, optionally containing 1 to 5 oxygen atoms in the main chain.

Similarly, JP 2009173644 (DAIKININD LTD) discloses a method for manufacturing compounds of formula: Rf₁—(OCH₂CF₂CF₂)_(n1)OCX₁X₂CF₂ (Rf₂)_(n2)—COOM by ring-opening polymerization of 2,2,3,3-tetrafluorooxethane onto an acyl fluoride derivative of formula Rf₃—COF, wherein Rf₃ is a fluoroalkyl group optionally containing 1-5 oxygen atoms.

None of the above documents discloses or suggests to prepare block copolymers using acyl fluorides of (per)fluoropolyethers complying with certain molecular weight requirements as precursors to be used as oils with improved anti-wear properties or with improved hydrophobic or oilophobic properties.

SUMMARY OF INVENTION

It has now been found that certain block copolymers comprising (per)fluoropolyether segments having a molecular weight higher than 400 g/mol are endowed with improved anti-wear properties or with improved hydrophobic or oilophobic properties.

Accordingly, the present invention relates to a (per)fluoropolyether block copolymer comprising:

A) a fluoropolyoxyalkylene segment (chain R_(a)) comprising one or more units of formula (CHXCF₂CF₂O)— in which X is hydrogen or fluorine;

B) a (per)fluoropolyoxyalkylene segment (chain R_(f)), that is to say a segment comprising recurring units having at least one catenary ether bond and at least one fluorocarbon moiety, said (per)fluoropolyoxyalkylene segment being different from chain R_(a) and having a molecular weight higher than 400 g/mol.

For the purposes of the present description, the expression “(per)fluorinated segment” means that the segment may be fully or partially fluorinated. Likewise, the expression “perfluoro(oxy)alkyl group” reported below is intended to mean a perfluoroalkyl group containing catenary ether bonds.

The (per)fluoropolyoxyalkylene segment (chain R_(f)) is preferably a chain comprising recurring units having general formula —(CF₂)_(k)—CFZ—O—, wherein k is an integer of from 0 to 3 and Z is selected between a fluorine atom and a C₁-C₆ perfluoro(oxy)alkyl group.

More preferably, chain R_(f) complies with formula: —(CF₂CF₂O)_(p)(CFYO)_(q)(CF₂CFYO)_(r)(CF₂O)_(s)(CF₂(CF₂)_(z)CF₂O)_(t)—, the recurring units being statistically distributed along the (per)fluoropolyoxyalkylene chain, wherein: Y is a C₁-C₅ perfluoro(oxy)alkyl group; z is 1 or 2; p, q, r, s, t are integers ≧0, selected in such a way as to comply with the above-mentioned molecular weight requirement.

Even more preferably, chain R_(f) complies with formula: —(CF₂CF₂O)_(p′)(CF₂O)_(q′)—, wherein: p′ and q′ are integers ≧0 and are selected in such a way as they comply with the above-mentioned molecular weight requirement; still more preferably, the p/q or p′/q′ ratio is 2.

In a first aspect, the block copolymer of the invention preferably complies with formula (IA) below: R_(a)—R_(f)—R_(a′)  (IA) in which chain R_(f) is as defined above and chain R_(a) is selected from any one of groups (II)-(VI) as defined further below and R_(a′) is the same as R_(a) or is a (C₁-C₅)(per)fluoroalkyl group optionally containing hydrogen and/or chlorine atoms. In the following, the block copolymers complying with formula (IA) above will be referred to either as block copolymers of formula (IA), or block copolymers (IA), or compounds of formula (IA) or compounds (IA). Group (II) complies with formula: (CH₂CF₂CF₂O)_(n)CH₂CF₂C(O)F  (II) wherein n is an integer equal to or higher than 1, preferably comprised between 1 and 100, more preferably comprised between 5 and 15.

Group (III) complies with formula: (CH₂CF₂CF₂O)_(n)CH₂CF₂C(O)R  (III) wherein: n is as defined above and R is hydrogen, a hydroxy group or a W—R¹ group. In group W—R¹, W is a bond or is selected from —O—, —OC(O)—, —NHC(O)—, —NH—, —NR¹′—, wherein R¹′ is a straight or branched C₁-C₆ alkyl group, and R¹ is selected from: a straight or branched, saturated or unsaturated (C₁-C₃₆)hydrocarbon chain; a (C₅-C₁₄)cycloalkyl or a (C₅-C₁₄)cycloalkyl(C₁-C₁₀)alkyl group, the cycloalkyl moiety being optionally substituted with one or more (C₁-C₄)straight or branched alkyl chains; a (C₆-C₁₄)aryl or a (C₁-C₁₀)alkyl(C₆-C₁₄)aryl group and a group of formula —R^(A)—CR_(H)═CH₂ in which R_(H) is hydrogen or a (C₁-C₃₄)straight or branched, saturated or unsaturated hydrocarbon chain and R^(A) is selected from: —NH—R^(B)—O—CO—  (j); —NH—R^(B)—NHCOO—R^(B)—OCO—  (jj); —R^(B)—O—CO—  (jjj); R^(B) being a divalent group selected from: a (C₁-C₁₀)aliphatic group, a (C₅-C₁₄)cycloaliphatic group, a (C₆-C₁₄)aromatic or a (C₁-C₁₀)alkyl(C₆-C₁₄ aryl) group.

Group (IV) complies with formula: (CH₂CF₂CF₂O)_(n)CH₂CF₂CH₂OR′  (IV) wherein n is as defined above and R′ is hydrogen or a (CHR²CHR³O)_(m)—R⁴ group in which: R² and R³ are both hydrogen or one is hydrogen and the other is methyl; m is 0 or an integer equal to or higher than 1; R⁴ is selected from:

-   -   hydrogen, with the proviso that, when m is 0, R⁴ is not         hydrogen;     -   a straight or branched, saturated or unsaturated         (C₁-C₃₆)hydrocarbon chain; a (C₅-C₁₄)cycloaliphatic or a         (C₁-C₁₀)alkyl(C₅-C₁₄)cycloalkyl group; a (C₆-C₁₄)aromatic or a         (C₁-C₁₀)alkyl(C₆-C₁₄)aromatic group;     -   a P(O)R⁵R⁶ group, in which R⁵ and R⁶ are, independently of each         other, selected from hydroxy and —O⁻X⁺ groups, in which X⁺ is         selected from Li⁺, Na⁺, K⁺, (NH₃R′)⁺, (NH₂R′R″)⁺ and         (NHR′R″R′″)⁺ wherein R is H or a linear or branched         (C₁-C₂₂)alkyl group optionally containing one or more —OH         groups, and R′, R″ and R′″, equal to or different from each         other, are linear or branched (C₁-C₂₂)alkyl groups optionally         containing one or more —OH groups or optionally linked to each         other to form N-heterocyclic groups;     -   a COR⁷ group, in which R⁷ is a straight or branched, saturated         or unsaturated (C₁-C₃₆)hydrocarbon chain, preferably a         —CR_(H)═CH₂ chain, wherein R_(H) is hydrogen or a straight or         branched, saturated or unsaturated (C₁-C₃₄)hydrocarbon chain, or         R⁷ is a (C₅-C₁₄)cycloaliphatic or a         (C₁-C₁₀)alkyl(C₅-C₁₄)cycloalkyl group; a (C₆-C₁₄)aromatic or a         (C₁-C₁₀)alkyl(C₆-C₁₄)aromatic group;     -   a CONHR⁸ group, in which R⁸ is the same as R⁷ or a COR⁷ group,         in which R⁷ is as defined above;

a CO—R^(A)—CR_(H)═CH₂ group, wherein R_(H) is hydrogen or a straight or branched, saturated or unsaturated (C₁-C₃₄)hydrocarbon chain and R_(A) is selected from the group consisting of: —NH—R^(B)—O—CO—  (j); —NH—R^(B)—NHCOO—R^(B)—OCO—  (jj); —R^(B)—O—CO—  (jjj); R^(B) being a divalent group selected from a (C₁-C₁₀)aliphatic group, a (C₅-C₁₄)cycloaliphatic group, a (C₆-C₁₄)aromatic or a (C₁-C₁₀)aliphatic(C₆-C₁₄)aromatic group. Group (V) complies with formula: (CHYCF₂CF₂O)_(n)CHYCF₃  (V) wherein n is as defined above and Y is fluorine or hydrogen. Group (VI) complies with formula: (CH₂CF₂CF₂O)_(n)CH₂CF₂H  (VI) wherein n is as defined above.

In a second aspect, the block copolymer of the invention preferably complies with formula (IB):

in which:

-   -   R_(f) is as defined above;     -   R_(a) is a group of formula         (CH₂CF₂CF₂O)_(n)CH₂CF₂CH₂O(CHR²CHR³O)_(m) in which R² and R³ are         as defined above and m is 0 or an integer equal to or higher         than 1;     -   R_(a′) is the same as R_(a) or is a (C₁-C₅)(per)fluoroalkyl         group;     -   Z is a polar group of formula —O⁻ M+, wherein M is selected from         hydrogen, a monovalent metal, preferably an alkali metal         selected from Li, Na, K, an ammonium radical selected from         NR_(a)R_(b)R_(c)R_(d), wherein each of R_(a), R_(b), R_(c) and         R_(d) is, independently, a hydrogen atom or a         (C₁-C₂₂)hydrocarbon group, optionally fluorinated, or a polar         group of formula —O⁻)₂M′²⁺, wherein M′ is a divalent metal,         preferably an alkaline earth metal selected from Ca and Mg;     -   x is 3 or 4, with the proviso that:         when x is 3, p_(f) is an integer from 1 to 6, q_(z) is 0 or an         integer from 1 to 5 and p_(f)+q_(z) is 6;         when x is 4, p_(f) is an integer from 1 to 8, q_(z) is 0 or an         integer from 1 to 7 and p_(f)+q_(z) is 8         and with the proviso that, when R_(a′) is a         C₁-C₅(per)fluoroalkyl group, p_(f) is 1.

In a third aspect, the block copolymers of the invention preferably further comprise a block deriving from a diol or a diamine; more preferably, the invention comprises (per)fluoropolyether block copolymers of formula (IA) as defined above in which one or both of chain R_(a) and R_(a′) are linked to a diol compound of formula HO—R_(diol)—OH through an urethane or an ester moiety. The copolymers according to this third aspect of the invention will be herein after referred to also as compounds (IC).

In a compound of formula HO—R_(diol)—OH, R_(diol) is a C₂-C₁₄ hydrocarbon group, optionally containing one or more cycloaliphatic or aromatic groups and/or additional functional groups. Examples of diols of formula HO—R_(diol)—OH are disclosed in EP 2151239 A (SOLVAY SOLEXIS).

According to a preferred aspect of the invention, additional functional groups in R_(diol) are ionisable anionic and/or cationic groups, i.e. groups which, under appropriate pH conditions, form anionic or cationic groups.

For the purposes of the present invention, suitable ionisable anionic groups are, for example, carboxylic acid groups of formula —COOH, sulphonic acid groups of formula —SO₃H, phosphoric acid groups of formula —PO₄H₂, while suitable ionisable cationic groups are amine groups, which may be either comprised in the R_(doil) backbone, according to formula —N(R_(N))—, wherein R_(N) is selected from H and hydrocarbon groups having 1 to 6 carbon atoms, or comprised in side groups having formula —N(R_(N1))(R_(N2)), wherein R_(N1) and R_(N2), equal to or different from one another, are independently selected from hydrogen and hydrocarbon groups containing from 1 to 6 carbon atoms.

A first preferred example of an R_(diol) containing ionisable groups is a carboxylic-containing chain (R′_(HC)):

wherein T is a hydrocarbon trivalent group selected from a linear or branched C₁-C₁₂ hydrocarbon chain, a C₃-C₁₂ cycloaliphatic group or a C₆-C₁₂ aromatic group. More preferably, an (R′_(HC)) chain is selected from any one of the followings:

Even more preferably, chain (R′_(HC)) complies with formula:

A second preferred example of an R_(doil) containing an ionisable group is an amine-containing chain (R″_(HC)):

wherein R_(N1) and R_(N2) have the same meanings as defined above, Q is an hydrocarbon trivalent group selected from a linear or branched C₂-C₁₂ hydrocarbon chain, a C₃-C₁₂ cycloaliphatic group or a C₆-C₁₂ aromatic group. Chain (R″_(HC)) preferably complies with formula:

wherein R_(N1) and R_(N2) have the same meanings as defined above; more preferably, R_(N1) and R_(N2) are independently selected from linear or branched C₁-C₄ alkyl groups; m, m′ and m″ are 0 or an integer from 1 to 4, with the proviso that at least one of m and m″ is not zero and R_(Q) is H or a linear or branched C₁-C₄ alkyl group. Preferred amine-containing chains (R″_(HC)) are those of formulae —CH(CH₂—N(C₂H₅)₂)—CH₂— and —CH(CH₂—N(CH₃)₂)—CH₂—.

A third preferred example of an R_(diol) containing an ionisable group is an amine-containing chain (R′″_(HC))

wherein R_(N1) has the same meanings defined above; preferably, R_(N1) is selected from C₁-C₄ alkyl groups and K and K′ are divalent hydrocarbon groups having from 1 to 6 carbon atoms.

A preferred group of block copolymers (IC) is the one in which the block deriving from an HO—R_(diol)—OH is linked to a chain R_(a) or to chains R_(a) and R_(a′) through a urethane moiety complying with formula:

wherein E is a divalent hydrocarbon group, linear or branched, preferably a C₁-C₁₂ hydrocarbon group, optionally comprising one or more C₃-C₁₂ cycloaliphatic or C₆-C₁₂ aromatic groups. Preferably, group E is selected from any one of the following:

wherein:

-   -   n_(H) is an integer from 1 to 12, preferably equal to 6;     -   J is a divalent bridging group selected from: a single bond; a         methylene group (—CH₂—); an oxygen atom (—O—); a —C(CH₃)₂—         group; a —C(CF₃)₂— group; a —SO₂— group; a —C(O)— group;         preferably J is a methylene group;     -   each of R_(A), R_(B), R_(C) and R_(D), equal or different at         each occurrence, is independently a halogen atom (e.g. Cl, Br,         F), a C₁-C₆ hydrocarbon group (e.g. methyl, ethyl), a         substituent group like notably —OR_(H), —NR_(H′)R_(H″),         —C(O)—R_(H′″), wherein R_(H), R_(H′), R_(H″) and R_(H′″), equal         to or different from each other, are independently at each         occurrence a hydrogen atom or a C₁-C₆ hydrocarbon group;     -   n_(A), n_(B) and n_(D) are independently integers comprised         between 0 and 4;     -   n_(C) is an integer comprised between 0 and 10.

Even more preferably, group E complies with formula:

Block copolymers (IC) in which a block deriving from an HO—R_(diol)—OH is linked to a chain R_(a) or to chains R_(a) and R_(a′) through a urethane moiety can be prepared by reacting a compound of formula (IA) as defined above in which one or both of R_(a) and R_(a′) are groups (IV) as defined above in which R′ is hydrogen with a diisocyanate ONC-E-CNO, in which E is as defined above, followed by reaction with at least one one diol of formula HO—R_(diol)—OH, wherein R_(diol) has the same meanings as defined above. A most particularly preferred group of copolymers according to this embodiment of the invention complies with formula (IC′):

in which R_(f), n, E and R_(diol) are as defined above and m is an integer higher than 1; according to a particularly preferred embodiment, E complies with formula:

and R_(diol) is a chain (R′_(HC)) of formula:

or is a chain (R″_(HC)) of formula:

Preferred compounds of formulae (IA)-(IC) are those in which chain R_(f) complies with formula —(CF₂CF₂O)_(p′)(CF₂O)_(q′)—, wherein p′ and q′ are integers ≧0 and are selected in such a way as they comply with the above-mentioned molecular weight requirement. More preferably, the p′/q′ ratio is 2.

Preferred compounds of formulae (IA)-(IC) are also those in which R_(a′) is the same as R_(a) or those in which chain R_(a′) differs from chain R_(a) only the number of CHXCF₂CF₂O— units.

Preferred compounds of formulae (IA)-(IC) are also those in which n ranges from 1 to 100, preferably from 1 to 50, even more preferably from 5 to 15.

A first particularly preferred group of compounds of formula (IA) are those in which one or both chains R_(a) or R_(a′) contain an acrylate function. In this group of compounds, particularly preferred those in which:

-   -   chain R_(f) complies with formula —(CF₂CF₂O)_(p′)(CF₂O)_(q)′—,         wherein p′ and q′ are integers ≧0 and are selected in such a way         as they comply with the above-mentioned molecular weight         requirement;     -   R_(a) is selected from: a group (IV) as defined above in which n         ranges from 5 to 15 and R′ is a (CHR²CHR³O)_(m)—R⁴ group in         which R⁴ is a CO—R_(A)—CR_(H)═CH₂ group as defined above,         wherein R^(A) is a group of formula (j);     -   R_(a′) is the same as a R_(a).

A second particularly preferred group of block copolymers of formula (IA) is the one in which:

-   -   chain R_(f) complies with formula —(CF₂CF₂O)_(p′)(CF₂O)_(q′)—,         wherein p′ and q′ are integers ≧0 and are selected in such a way         as they comply with the above-mentioned molecular weight         requirement;     -   R_(a) is a group (V) as defined above in which n ranges from 5         to 15; and     -   R_(a′) is the same as R_(a).

A third particularly preferred group of block copolymers of formula (IA) is the one in which:

-   -   chain R_(f) complies with formula —(CF₂CF₂O)_(p′)(CF₂O)_(q′)—,         wherein p′ and q′ are integers ≧0 and are selected in such a way         as they comply with the above-mentioned molecular weight         requirement;     -   chain R_(a) is a group of formula (VI) as defined above in which         n ranges from 5 to 15; and     -   R_(a′) is the same as R_(a).

The compounds of formula (IA) in which one or both of R_(a) and R_(a′) are groups (II) can be prepared by ring-opening reaction of 2,2,3,3-tetrafluorooxethane in the presence of organic or inorganic fluorides. For the purposes of the present invention, the expression “ring-opening reaction” means a reaction whereby 2,2,3,3-tetrafluorooxethane undergoes oligo- or polymerization. Typically, this reaction is carried out by reacting an acyl fluoride of a (per)fluoropolyether comprising an R_(f) chain as defined above with 2,2,3,3-tetrafluorooxethane in the presence of an organic or inorganic fluoride. Examples of organic fluorides are alkylammonium fluorides, such as tetrabutylammonium fluoride, while examples of inorganic fluorides are lithium fluoride, sodium fluoride, potassium fluoride, calcium fluoride, barium fluoride, magnesium fluoride and cesium fluoride; according to a preferred embodiment, the metal fluoride is cesium fluoride. The reaction is usually carried out in an aprotic solvent, such as acetonitrile, or a glycol dialkyl ether; among glycol dialkyl ethers, diglyme and tetraglyme are preferred. The reaction is preferably carried out at a temperature ranging from about −30° C. to about +30° C., more preferably from about −5° C. to about +10° C., even more preferably at about 0° C. The reaction product, i.e. the compound in which one or both of R_(a) and R_(a′) are groups (II), i.e. groups which contain one or two acyl fluoride terminals, is useful as intermediate for the preparation of further preferred neutral or functionalized block copolymers of the invention, in particular for the preparation of the compounds of formula (IA) in which one or both of R_(a) and R_(a′) are any one of groups (III)-(VI).

In particular, for the preparation of the compounds of formula (IA) in which one or both of R_(a) and R_(a′) are groups (III) in which R is a hydroxy group, a block copolymer of formula (I) in which one or both of R_(a) and R_(a′) are groups (II) is submitted to hydrolysis, while for the preparation of the compounds of formula (IA) in which one or both of R_(a) and R_(a′) are groups (III) wherein R is a W—R¹ group in which W is O and R¹ is as defined above, a compound of formula (II) is reacted with an alcohol R¹OH, wherein R¹ is as defined above.

The compounds of formula (IA) in which one or both of R_(a) and R_(a′) are groups (III) in which R is hydrogen can be prepared according to conventional methods for the preparation of aldehydes, for example by catalytic reduction or by reduction with hydrides of a compound of formula (IA) in which one or both of R_(a) and R_(a′) are groups (III) wherein R is a W—R¹ group in which W is O and R¹ is hydrogen or an alkyl group, typically a C₁-C₄ alkyl group.

The compounds of formula (IA) in which one or both of R_(a) and R_(a′) are groups (III) in which R is a W—R¹ group wherein W is a bond and R¹ is as defined above can be prepared according to conventional methods for the preparation of ketones, for example reaction of a compound of formula (IA) in which one or both of R_(a) and R_(a′) are groups (III) wherein R is a W—R¹ group in which W is O and R¹ is an alkyl group, typically a C₁-C₄ alkyl group with a carbanion of a compound R¹H.

The compounds of formula (IA) in which one or both of R_(a) and R_(a′) are groups (III) in which R is a W—R¹ group in which W is NH and R¹ is as defined above can be prepared according to conventional methods for the preparation of amides, by reaction of a compound of formula (IA) in which one or both of R_(a) and R_(a′) are groups (II) with an amine R¹—NH₂ or with an amine R¹R¹′NH wherein R¹ and R^(1′) are defined above.

The compounds of formula (IA) in which one or both of R_(a) and R_(a′) are groups (III) in which R is a W—R¹ group in which W is —OC(O)— and R¹ is as defined above can be prepared from compounds of formula (IA) in which one or both of R_(a) and R_(a′) are groups (III) in which R is OH according to conventional methods for the preparation of anhydrides, for example by reaction with an acid of formula R¹COOH in the presence of a dehydrating agent.

The compounds of formula (IA) in which one or both of R_(a) and R_(a′) are groups (III) in which R is a W—R¹ group in which W is —NHC(O)— and R¹ is as defined above can be prepared from a compound of formula (IA) in which one or both of R_(a) and R_(a′) are groups (II) or (III) in which R is OH or a reactive derivative thereof, preferably the chloride derivative, according to conventional methods for the preparation of dicarboxylmides, for example by reaction with an organic primary amide R¹CONH₂.

The compounds of formula (IA) wherein one or both of R_(a) and R_(a′) are groups (III) wherein R is a W—R¹ group in which W is as defined above R¹ is R^(A)—R_(H)═CH₂, with R^(A) being selected from any one of groups (j)-(jj) as defined above, can also be synthesised by reaction of a compound of formula (IA) in which one or both R_(a) and R_(a′) are groups (II) or (III) in which R is a hydroxy group or a reactive derivative thereof, preferably the chloride derivative, with suitable precursors of the R^(A)—R_(H)═CH₂ moiety, following a reaction scheme similar to that descried below for the preparation of analogous compounds in which one or both of R_(a) and R_(a′) are groups (IV).

The compounds of formula (IA) in which one or both of R_(a) and R_(a′) are groups (IV) in which R′ is hydrogen can be prepared by reduction of block polymers of formula (I) in which one or both of R_(a) and R_(a′) are groups (III) in which R is a hydroxy group or a W—R¹ group wherein W is oxygen and R¹ is an alkyl group, typically a C₁-C₄ straight or branched alkyl group, preferably an ethyl group; preferably, the reduction is carried out with a metal hydride, typically LiAlH₄ or NaBH₄, in an appropriate solvent, such as an alcohol, preferably methanol or ethanol, an ether or a glycol, preferably diethylether or diglyme. As an alternative, the reduction can be carried out under hydrogen pressure in the presence of a homogeneous or heterogeneous metal-supported catalyst; preferred catalysts are those based on metals of the VIII group of the Periodic Table, preferably Pt, Rh, Ru, more preferably carbon-supported ruthenium. This reduction method is disclosed in U.S. Pat. No. 7,132,574 to Solvay Solexis.

The compounds of formula (IA) in which one or both of R_(a) and R_(a′) are groups (IV) in which R′ is hydrogen can in turn be used as precursors of compounds of formula (IA) in which one or both of Ra and Ra′ are groups (IV) in which R′ is a (CHR²CHR³O)_(m)—R₄ group. For the preparation of the compounds in which m is 0, a compound of formula (IA) in which one or both of R_(a) and R_(a′) are groups (IV) in which R′ is hydrogen is directly submitted to a reaction that allows the insertion of a group of formula R⁴ other than hydrogen, while for the preparation of the block copolymers in which R′ is a (CHR²CHR³O)_(m)—R₄ group wherein m is higher than 1, a block copolymer of formula (IA) in which one or both of R_(a) and R_(a′) are groups (IV) in which R′ is hydrogen is first reacted with ethylene oxide, propylene oxide, ethylene carbonate or propylene carbonate in the presence of an inorganic or organic base catalyst, for example an alkaline or terrous-alkaline hydroxide, or a tertiary amine, to provide a block copolymer of formula (IA) wherein one or both of R_(a) and R_(a′) are groups (IV) wherein R′ is (CHR²CHR³O)_(m)—R⁴ with R⁴ being hydrogen. This block copolymer is then submitted to a reaction that allows the introduction of the R⁴ group. Examples of reactions that allow the introduction of a R⁴ group other than hydrogen are described below in greater detail.

The synthesis of compounds of formula (IA) in which one or both of R_(a) and R_(a′) are groups (IV) in which R′ is a (CHR²CHR³O)_(m)—R⁴ in which R⁴ is a hydrocarbon chain, a cycloaliphatic, an alkylcycloaliphatic, an aromatic or an alkylaromatic group as defined above can be prepared by transforming the hydroxy group in a compound of formula (IA) in which one or both of R_(a) and R_(a′) are groups (IV) in which R′ is a (CHR²CHR³O)_(m) group wherein R⁴ is hydrogen into a leaving group, such as a nonaflate, a triflate or a tosylate group, followed by reaction with a reactive compound containing a R⁴ group, typically an alcoholate. As an alternative, the hydroxy group can be transformed into an alkoxy group and reacted with an alcohol R⁴OH in which the hydroxy group has been transformed into a leaving group, such as a nonaflate, triflate or tosylate.

The compounds of formula (IA) in which one or both of R_(a) and R_(a′) are groups (IV) in which R′ is a (CHR²CHR³O)_(m)—R⁴ group with R⁴ being a P(O)R⁵R⁶ group, in which R⁵ and R⁶ are as defined above, can be prepared, for instance, by reacting a block copolymer of formula (I) in which one or both of R_(a) and R_(a′) are groups (IV) in which R′ is hydrogen or a (CHR²CHR³O)_(m)—R⁴ group with m equal to or higher than 1 and R⁴ being hydrogen with phosphoryl trichloride (POCl₃) in the presence of a base as HCl acceptor or with phosphorus pentoxide (P₂O₅) or with pyrophosphoric acid or with a polyphosphoric acid, and optionally salifying the resulting compound.

The compounds of formula (IA) in which one or both of R_(a) and R_(a′) are groups (IV) in which R′ is a (CHR²CHR³O)_(m)—R⁴ group with R⁴ being a COR⁷ group as defined above can be prepared by reaction of a compound of formula (I) in which one or both of R_(a) and R_(a′) are groups (IV) in which R′ is hydrogen or a (CHR²CHR³O)_(m)—R⁴ group wherein m is higher than 1 and R₄ is hydrogen with a carboxylic acid R⁷CO₂H or with a reactive derivative thereof; for the purposes of the present description, the expression “reactive derivative” of carboxylic acids is meant to comprise chlorides, bromides, iodides and esters.

The compounds of formula (IA) in which one or both of R_(a) and R_(a′) are groups (IV) in which R′ is a (CHR²CHR³O)_(m)—R⁴ group with R⁴ being a CONHR⁸ group wherein R⁸ is the same as R⁷ can be prepared by reacting a compound of formula (IA) in which one or both of R_(a) and R_(a′) are groups (IV) in which R′ is hydrogen or a (CHR²CHR³O)_(m)—R⁴ group wherein m is equal to or higher than 1 and R⁴ is hydrogen with an isocyanate R⁸—N═C═O. The compounds of formula (IA) in which one or both of R_(a) and R_(a′) are groups (IV) in which R′ is a (CHR²CHR³O)_(m)—R⁴ group with R⁴ being a CONHR⁸ group wherein R⁸ is a COR⁷ group can be prepared by reaction of a compound of formula (IA) in which one or both of R_(a) and R_(a′) are groups (IV) in which R′ is hydrogen or a (CHR²CHR³O)_(m)—R⁴ group wherein m is equal to or higher than 1 and R⁴ is hydrogen with dichlorocarbonate and by reacting the resulting compound with an amide of formula R⁷CONH₂.

The compounds of formula (IA) in which one or both of R_(a) and R_(a′) are groups (IV) in which R′ is a (CHR²CHR³O)_(m)—R⁴ group with R⁴ being a CO—R^(A)—CR_(H)═CH₂ group in which R^(A) is —NH—R^(B)—O—CO— a can be prepared by reaction of a compound (IA) in which one or both of R_(a) and R_(a′) are groups (IV) in which R′ is hydrogen or a (CHR²CHR³O)_(m)—R⁴ group wherein m is equal to or higher than 1 and R⁴ is hydrogen with dichlorocarbonate, followed either by reaction with an amine of formula NH₂—R^(B)—O—CO—CR_(H)═CH₂ or by reaction of an aminoalcohol NH₂—R^(B)—OH, followed by reaction with a carboxylic acid of formula CH₂═CR_(H)CO₂H or with a reactive derivative thereof.

The compounds of formula (IA) in which one or both of R_(a) and R_(a′) are groups (IV) in which R′ is a (CHR²CHR³O)_(m)—R⁴ group with R⁴ being a CO—R^(A)—CR_(H)═CH₂ group in which R^(A) is NH—R^(B)—NHCOO—R^(B)—OCO—, wherein R^(B) is as defined above, can be prepared by reaction of a compound (IA) in which one or both of R_(a) and R_(a′) are groups (IV) in which R′ is hydrogen or a (CHR²CHR³O)_(m)—R⁴ group with m equal to or higher than 1 and R⁴ being hydrogen with dichlorocarbonate, followed by reaction with a diamine NH₂—R^(B)—NH₂ to provide an intermediate in which one or both of R_(a) and R_(a′) comply with formula (CF₂CF₂CF₂O)_(n)CH₂CF₂CH₂ OCONHR^(B)NH₂. This intermediate can be further reacted with dichlorocarbonate and a diol HO—R^(B)—OH to provide a further intermediate in which one or both of R_(a) and R_(a′) comply with formula (CF₂CF₂CF₂O)_(n) CH₂CF₂CH₂OCONHR^(B)NHCOOR^(B)—OH which, by reaction with a carboxylic acid of formula CH₂═CRHCO₂H or with a reactive derivative thereof, affords the aforementioned compound (IA).

The compounds of formula (IA) in which one or both of R_(a) and R_(a′) are groups (IV) in which R′ is a (CHR²CHR³O)_(m)—R⁴ group with R⁴ being a CO—R_(A)—CR_(H)═CH₂ group in which R_(A) is R^(B)—O—CO— can be prepared by reaction of a compound of formula (IA) in which one or both of R_(a) and R_(a′) are groups (IV) in which R′ is hydrogen or a (CHR²CHR³O)_(m)—R⁴ group wherein m is equal to or higher than 1 and R⁴ is hydrogen with an acid of formula CH₂═CR_(H)—R^(A)—CO₂H or with a reactive derivative thereof; as an alternative, a compound of formula (IA) in which one or both of R_(a) and R_(a′) are groups (IV) in which R′ is hydrogen or a (CHR²CHR³O)_(m)—R⁴ group wherein m is equal to or higher than 1 and R⁴ is hydrogen can be reacted with a hydroxy acid PO—R^(B)—COOH, wherein P is a hydroxy-protecting group, or with a reactive derivative thereof, to provide an intermediate in which one or both of R_(a) and R_(a′) comply with formula (CF₂CF₂CF₂O)_(n)CH₂ CF₂CH₂O(CHR²HR³O)_(m)COR^(B)—OP which, after removal of the protecting group and reaction with a carboxylic acid CH₂═CHR_(H)—COOH or with a derivative thereof, affords the desired aforementioned compound (IA).

The compounds of formula (IA) in which one or both of R_(a) and R_(a′) are groups (V) as defined above can be prepared by fluorinating a compound of formula (I) in which one or both of R_(a) and R_(a′) are groups (III) as defined above, wherein R is a hydroxy group. The reaction is typically carried out in a fluorinated solvent selected from (per)fluoroalkyl compounds and hydrofluoroethers, such as perfluorobutyl tetrahydrofurane, perfluoropropyl tetrahydropyrane, Vertrel® XF 2,3-dihydrodecafluoropentane, or HFE® 7100 methoxy-nonafluorobutane, at a temperature ranging preferably from −40 to +30° C., more preferably from −30 to +10° C., even more preferably from −30 to 0° C., bubbling fluorine, optionally diluted in helium, at a molar ratio of from 1:1 to 1:0.01.

The compounds of formula (IA) in which one or both of R_(a) and R_(a′) are groups (VI) as defined above can be prepared by hydrogenation of a compound of formula (I) in which one or both of R_(a) and R_(a′) are groups (III) as defined above, wherein R is a hydroxy group. The reaction is typically carried out in a solvent selected from ethers and glycols, preferably glyme, at a temperature ranging preferably from 150° C. to 250° C., more preferably from 180° C. to 220° C., in the presence of an excess of an organic or inorganic base, such as NH₄OH, KOH, NaOH and CsOH.

The block copolymers of formula (IIB) can be prepared by reaction of a compound of formula (IA) in which one or both of R_(a) and R_(a′) are groups (II) as defined above in which R′ is either hydrogen or a (CHR²CHR³O)_(m)—R⁴ group in which R² and R³ are as defined above, m is 1 or an integer higher than 1 and R⁴ is hydrogen with hexafluorotriphosphazene or octachlorotetraphosphazene. Typically, the aforementioned compound (IA) is dissolved in a fluorinated or hydrofluorinated solvent with a boiling point ranging from 20 to 150° C., preferably from 40 to 100° C., such as perfluorobutyl tetrahydrofurane or perfluoropropyl tetrahydropyrane; hexafluorotriphosphazene or octachlorotetraphosphazene is usually added to the reaction mixture in the form of an alkaline solution. The reaction is usually carried out at a temperature ranging from room temperature to 100° C., preferably from 40 to 80° C., more preferably form 60 to 80° C. For the preparation of compounds (IIB) in which q_(z) is an integer ranging from 1 to 5 or 1 to 7, the reaction product is salified with an appropriate compound.

The block copolymers of the invention, in particular the compounds of formula (IA) in which one or both of R_(a) ad R_(a′) contain an acrylate moiety, in particular a methacrylate moiety, are characterised by low surface energy, high chemical resistance and they are able to impart to materials and coatings self-cleaning properties and oil-repellence properties; therefore a further object of the present invention is the use of the block copolymers of the invention as water- and oil-resistance agents.

Water and oil resistance compositions containing one or more block copolymers of the invention in admixture with additives or vehicles are a still further object of the invention.

The block copolymers of the invention and the compositions containing them can be applied to a variety of substrates, such as glass or cellulose substrates, especially those used in packaging applications.

The block copolymers of formula (IA) in which one or both of R_(a) and R_(a′) contain an acrylate function can advantageously be used in nanolithography processes for reproducing (nano)patterns using flexible moulds; for this purpose, the compounds (IA) are applied to a patterned template surface and submitted to UV radiations in the presence of a photoinitiator. A non exhaustive list of photoinitiators and their amounts is reported, for example, in EP 2221664 A (SOLVAY S.A.).

The block copolymers of the invention, in particular the compounds of formula (IA) in which one or both of R_(a) and R_(a′) are groups (V) or (VI) as defined above are endowed with improved lubricant properties. Furthermore, the block copolymers of the invention are advantageous in that they can be used without anti-wear additives, which need usually be added to (per)fluorinated oils. Particularly advantageous are the compounds of formula (IA) in which:

-   -   chain R_(f) complies with formula —(CF₂CF₂O)_(p′)(CF₂O)_(q′)—,         wherein p′ and q′ are integers ≧0 and are selected in such a way         as they comply with the above-mentioned molecular weight         requirement;     -   R_(a) is a group of formula (V) or (VI) as defined above in         which n ranges from 5 to 15; and     -   R_(a′) is the same as R_(a).

Therefore, a further object of the invention is the use of the block copolymers of the invention as lubricants.

Lubricant compositions containing one or more block copolymers of the invention are a still further object of the invention.

The block copolymers of the invention can also be advantageously used as co-macromers, in particular those containing an acrylate moiety, for the synthesis of other polymers, or for the preparation of fluorinated coatings. Furthermore, the block copolymers of the invention can be used for preparing surface modifiers or surface-treating agents.

The following examples illustrate the invention in greater detail without limiting its scope.

Should the disclosure of any patents, patent applications and publications which are herein incorporated by reference be in conflict with the present application to the extent that it may render a term unclear, the present description shall take precedence.

PREPARATIVE EXAMPLES Raw Materials

2,2,3,3-Tetrafluoroxethane was prepared from ethylene and formaldehyde according to known methods. (Per)fluoropolyethers acyl precursors were synthesised according to the procedure disclosed in U.S. Pat. No. 3,847,978 (MONTEDISON SPA), U.S. Pat. No. 4,755,330 (AUSIMONT SPA), U.S. Pat. No. 4,755,330 (AUSIMONT SPA), U.S. Pat. No. 6,919,479 (SOLVAY SOLEXIS SPA). The other chemicals and solvents are commercially available; in some instances, solvents were distilled before use.

In the following examples, R_(f′) stands for —OCF₂CF₂O(CF₂CF₂O)_(p)(CF₂O)_(q)CF₂CF₂O; p/q=2

Example 1 Synthesis of R_(f′)[(CH₂CF₂CF₂O)_(7.2)CH₂CF₂COOH]₂

A 100 ml, 3-necked flask, kept under nitrogen and equipped with a magnetic stirrer, a thermometer, a condenser and a dropping funnel, was charged with ethylenglicol dimethyl ether (16 ml), CsF (0.63 g; 4.2 meq), the diacyl fluoride F(O)CCF₂O(CF₂CF₂O)_(p)(CF₂O)_(q)CF₂C(O)F (16 g; Mw=1477; Ew=770 p/q=2), 23 g of 2,2,3,3-tetrafluorooxethane (Mw=130) and stirred at 30° C.

After 3 hours, ¹⁹FNMR analysis of the crude mixture confirmed the complete reaction of the added monomer by monitoring the absence of its typical signals (−80 ppm and −120 ppm),

The reaction mixture was added with water and left under stirring for 1 hour in order to allow the title compound to separate.

The resulting mixture was then poured in a separator funnel and the lower phase was separated and distilled to afford 35 gr of the title compound R_(f′) [(CH₂CF₂CF₂O)_(7.2)CH₂CF₂COOH]₂ as residue.

Example 2 Synthesis of R_(f′)[(CH₂CF₂CF₂O)₄CH₂CF₂COOH]₂

A 100 ml, 3-necked flask, kept under nitrogen and equipped with a magnetic stirrer, a thermometer, a condenser and a dropping funnel was charged with ethylenglicol dimethyl ether (6 ml), CsF (2.65 g; 17.7 meq), the diacylfluoride F(O)CCF₂O(CF₂CF₂O)_(p)(CF₂O)_(q)CF₂COF (20 g; Mw=432; Ew=229 p/q=2), 56.8 g of 2,2,3,3-tetrafluorooxethane (Mw=130) and stirred at 30° C.

After 3 hours, ¹⁹FNMR analysis of the crude mixture confirmed the complete reaction of the added monomer by monitoring the absence of its very typical signals (−80 ppm and −120 ppm).

The reaction mixture was added with water and left under stirring for 1 hour in order to allow the title compound to separate.

The resulting mixture was then poured in a separator funnel and the lower phase was separated; distillation of the lower phase afforded 56 gr of the title compound R_(f′)[(CH₂CF₂CF₂O)₄CH₂CF₂COOH]₂ as residue.

Example 3 Synthesis of R_(f′)[(CHXCF₂CF₂O)_(7.2)CHXCF_(3]2)

A stainless steel reactor was charged with 300 g of a 5% (w/w) solution of the compound of example 1 in Galden A® perfluoropolyether and cooled to −25° C. The solution, kept under vigorous stirring, was then bubbled with a stream of F₂ diluted in helium (He:F₂=5:1 molar).

The reaction was checked by retrieving a solution sample, evaporating the solvent and analyzing the residue and monitoring by ¹⁹NMR analysis the disappearance of the preterminal CH₂ CF₂ COOH signal at −115 ppm an the appearance of a new signal at −75 ppm, attributed to the newly formed CF₃ end group. The reaction was considered completed when the conversion of the carboxylic acid was higher than 99%.

The reaction mixture was then bubbled with helium, let to warm to room temperature and distilled; 12.5 gr of R_(f′)[(CHXCF₂CF₂O)_(7.2)CHXCF₃]₂ (with H/X=4.1) were recovered as residue.

Example 4 Synthesis of R_(f′)[(CH₂CF₂CF₂O)_(7.2)CH₂CF₂H]₂

A 100 ml, 3-necked flask, kept under nitrogen and equipped with a magnetic stirrer, a thermometer, a condenser and a dropping funnel was charged with 15 ml of diethylenglicol, 15 g of the compound of example 1 and 3 g of KOH (50% aqueous solution). The resulting mixture was the heated up to 180° C. and let to stir for 8 hours.

The conversion of the reaction was checked monitoring by ¹⁹FNMR analysis of the crude mixture the disappearance of the preterminal CH₂ CF₂ COOH signal at −114 ppm and the formation of a new signal at −130 ppm, attributed to the newly formed CF₂H end group. The reaction was considered completed when the conversion of the carboxylic acid was >99%.

The reaction mixture was then brought to room temperature, added with 15 g of HCl (10% aqueous solution) and let to stir for 1 hour. The resulting mixture was then poured in a separator funnel and the lower phase was submitted to distillation to afford 13.2 gr title product R_(f′)[(CH₂CF₂CF₂O)_(7.2)CH₂CF₂H]₂ as distillation residue.

Example 5 Synthesis of R_(f′)[(CHXCF₂CF₂O)₄CHXCF_(3]2)

A stainless steel reactor was charged with 300 g of a 5% (w/w) solution of the compound of example 2 in Galden A® perfluoropolyether and cooled to −25° C. The solution, kept under vigorous stirring, was then bubbled with a stream of F₂ diluted in helium (He:F₂=5:1 molar).

The conversion was checked by retrieving a solution aliquot, evaporating the solvent and analyzing the residue and monitoring by ¹⁹NMR analysis the disappearance of the preterminal CH₂ CF₂ COOH signal at −114 ppm and the formation of a new signal at −75 ppm attributed to the newly formed CF₃ end group. The reaction was considered completed when the conversion of the carboxylic acid was higher than 99%.

The reaction mixture was then bubbled with helium, let to warm to room temperature and distilled; 12.0 gr of title product R_(f′)[(CHXCF₂CF₂O)₄CHXCF₃]₂ (with H/X=4.0) were recovered as residue.

Example 6 Synthesis of R_(f′)[(CH₂CF₂CF₂O)₅CH₂CF₂COOH]₂

A 100 ml, 3-necked flask, kept under nitrogen and equipped with a magnetic stirrer, a thermometer, a condenser and a dropping funnel was charged with 16 ml of ethylenglicol dimethyl ether, 1.3 g of CsF (Mw=152), 16 g of the diacylfluoride F(O)CCF₂O(CF₂CF₂O)_(p)(CF₂O)_(q)CF₂COF (Mw=704; Ew=382 p/q=2.2), 33 g of 2,2,3,3-tetrafluorooxethane (Mw=130) and let to stir at 30° C.

After 3 hours, ¹⁹FNMR analysis of the crude mixture confirmed the complete reaction of 2,2,3,3-tetrafluorooxethane (absence of its typical signals at −80 ppm and −120 ppm.

The reaction mixture was added with 15 g water and let to stir for 1 hour in order to allow the title product to separate from the reaction mixture.

The resulting mixture was then poured in a separator funnel and the lower phase was separated and distilled, to afford 47 gr of the title product as distillation residue.

Example 7 Synthesis of R_(f′)[(CH₂CF₂CF₂O)₅CH₂CF₂COOEt]₂

A 100 ml, 3-necked flask, kept under nitrogen and equipped with a magnetic stirrer, a thermometer, a condenser and a dropping funnel was charged with 16 ml ethylenglicol dimethyl ether, 1.3 g CsF (Mw=152), 16 g diacylfluoride F(O)CCF₂O(CF₂CF₂O)_(p)(CF₂O)_(q)CF₂COF (Mw=704; Ew=382 p/q=2.2), 33 g 2,2,3,3-tetrafluorooxethane (Mw=130) and let to stir at 30° C.

The reaction mixture was added with 20 g of anhydrous ethanol and let to stir for 1 hour.

The resulting solution was then poured in a separator funnel containing water and the lower phase was separated and submitted to distillation; 48 g title product were recovered as distillation residue.

Example 8 Synthesis of R_(f′)[(CH₂CF₂CF₂O)₅CH₂CF₂CH₂OH]₂

A 100 ml, 3-necked flask, kept under nitrogen and equipped with a magnetic stirrer, a thermometer, a condenser and a dropping funnel, was charged with 40 ml anhydrous ethanol and 1.1 g of NaBH₄ (Mw=40); the resulting solution was then cooled to 5° C. and 30 g of the compound of example 7R_(f′)[(CH₂CF₂CF₂O)₅CH₂CF₂COOEt]₂ (Ew=1188) were slowly added keeping the temperature below 10° C.

The conversion of the reaction was checked by ¹⁹NMR analysis, monitoring the disappearance of the preterminal CH₂ CF₂ COOEt signal at −114 ppm and the formation of the a signal at −117 ppm, attributed to the newly formed preterminal CH₂ CF₂ CH₂OH.

The reaction was considered completed when the conversion of the carboxylic ester was higher than 98%.

The reaction mixture was then let to warm to room temperatures and added with 30 g of an aqueous solution of HCl (10%), and left under stirring for 1 hour. The resulting mixture was then poured in a separator funnel and the lower phase was separated and distilled; 27.2 g of the title product R_(f′)[(CH₂CF₂CF₂O)₅CH₂CF₂CH₂OH]₂ were recovered as distillation residue.

Example 9 Synthesis of R_(f′)[(CH₂CF₂CF₂O)₅CH₂CF₂CH₂OC(O)NHCH₂CH₂OC(O)C(CH₃)═CH₂]₂

A 100 ml, 3-necked flask, kept under nitrogen and equipped with a magnetic stirrer, a thermometer, a condenser and a dropping funnel was charged with 50 ml anhydrous MEK, 30 μl of a solution of Sn dibutyl dilaurate in MEK (20% w/v) and 15 g of the compound of example 8R_(f′)[(CH₂CF₂CF₂O)₅CH₂CF₂CH₂OH]₂ (Ew=1144). The so obtained solution was then heated to 50° C. and 2.1 g of ethyl isocyanate methacrylate (Ew=155) were added and the solution was kept under stirring for 2 hours.

The reaction was followed by means of FTIR analysis, monitoring the disappearance of the typical isocyanate band at 2250 cm⁻¹. Moreover the conversion of the compound of example 8 was detected by ¹⁹NMR analysis, monitoring the disappearance of the preterminal CH₂ CF₂ CH₂OH at −117 ppm and the formation of a new signal at −115 ppm, attributed to the newly formed preterminal CH₂ CF₂ CH₂OC(O)NHCH₂CH₂OC(O)C(CH₃)═CH₂.

The reaction was considered completed when the conversion of the alcoholic group was higher than 98%; after removing the solvent by distillation, 16.5 g of the title compound, R_(f′)[(CH₂CF₂CF₂O)₅CH₂CF₂CH₂OC(O)NHCH₂CH₂CH₂OC(O)C(CH₃)═CH₂]₂, were recovered as residue.

Example 10 Synthesis of

A 250 ml, 4-necked flask kept under nitrogen and equipped with a mechanical stirrer, a thermometer and a condenser was charged with 30 g of the compound of example 8R_(f)[(CH₂CF₂CF₂O)₅CH₂CF₂CH₂OH]₂, Ew=1143), 4 g MEK, 6 g isophorone diisocyanate (IPDI, Ew=111) and 15 μl of a solution of Sn dibutyl dilaurate in MEK (20% w/v); the resulting solution was then heated up to 65° C. and left under stirring.

The reaction was checked by ¹⁹NMR analysis, monitoring the disappearance of the preterminal CH₂ CF₂ CH₂OH signal at −117 ppm and the appearance of a new signal at −115 ppm, attributed to the newly formed CH₂ CF₂ CH₂O C(O)NHR_(IPDI) group, wherein R_(IPDI) represent the R_(IPDI) moiety.

After 3 hrs the conversion of the compound of example 8 was higher than 98% and the reaction was considered completed.

The reaction mixture was then added with 14 g of a MEK solution containing 1.83 g of dimethylolpropionic acid (DMPA) and 1.1 g triethylamine (TEA, Ew=101) and left under stirring until FTIR analysis showed complete disappearance of the —NCO signal of the R_(IPDI) moiety at 2250 cm⁻¹.

Example 11 Synthesis of

A 250 ml 4-necked flask, kept under nitrogen and equipped with a mechanical stirrer, a thermometer and a condenser, was charged with 25 g of the compound of example 8R_(f)[(CH₂CF₂CF₂O)₅CH₂CF₂CH₂OH]₂, Ew=1143), 3 g MEK, 5 g IPDI (Ew=111) and 15 μl of a solution of Sn dibutyl dilaurate in MEK (20% w/v); the resulting solution was heated up to 65° C. and left under stirring.

The conversion of the reaction was checked by ¹⁹NMR analysis, monitoring the disappearance of the preterminal CH₂ CF₂ CH₂OH signal at −117 ppm and the formation of a new signal at −115 ppm, attributed to the newly CH₂ CF₂ CH₂O C(O)NHR_(IPDI) group, wherein R_(IPDI) represent the R_(IPDI) moiety.

After 3 hrs the conversion of the compound of example 8 was higher than 98% and the reaction was considered completed.

The reaction mixture was then added with 13 g of a MEK solution containing 1.7 g diethylaminopropanediol (DEAPD; Ew OH=73.5 and left under stirring until FTIR analysis showed complete disappearance of the —NCO signal of the R_(IPDI) moiety at 2250 cm⁻¹.

Applicative Tests

Test 1—Evaluation of Lubricant Properties

Anti-wear properties have been measured with a Tribometer SRV equipment, accordingly to ASTM 6425. The test temperature was 50° C., at 50 Hz, 1 mm stroke at 300N load for 2 h. The wear value was measured at the end of the test by visual inspection with a Motic Digital Microscope DM-143.

The results are reported in the table 1 below, in which a comparison among products obtained in examples 3 and 5 are compared with the following commercial perfluorinated oils having similar viscosity, as determined by applying the method ASTM D445:

Demnum® S65 PFPE (Daikin)

Demnum® S20 PFPE (Daikin)

Fomblin® Z03 PFPE (Solvay Solexis)

TABLE 1 Table 1 v (cSt) Wear (mm) Sample 40° C. average Std dev. Fomblin ® Z03 PFPE 18 1.15 0.03 Product of ex. 5 17 0.64 0.04 Product of ex. 3 65 0.75 0.04 Demnum ® S65 PFPE 65 0.86 0.01 Demnum ® S20 PFPE 25 0.96 0.04 Fomblin ® Z03 PFPE + 4% 18 0.87 0.01 Fomblin ® DA607 PFPE

It stems from table 1 that the products of examples 3 and 5 of the present invention cause a significantly lower wear with respect to perfluorinated commercial products having similar viscosity. It can also be appreciated that the addition of an anti-wear additive Fomblin® DA607 PFPE to Fomblin® Z03 PFPE, reduces wear from 1.15 down to 0.87, but the latter value is nonetheless higher than the value obtained using the product of example 5 alone. (0.64).

Test 2—Evaluation of Thermal Stability

The product of example 3 has been compared with Fomblin® 03 PFPE, which has a similar MW (3700 Mw and 4000 MW, respectively). TGA analysis, performed accordingly to ASTM E-1131, evidence two overlapping phenomena: weight loss due to evaporation (always occurring when non polymeric materials undergo the typical TGA temperature excursion) and weight loss due to degradation (i.e. fragmentation to more volatile byproducts).

The data reported in table confirm that volatility/degradation of the product of example 3 is lower than that of the reference commercial product.

TABLE 2 Evaporation weight Kinematic viscosity loss TGA Mw (cSt) T T NMR 20° C. 40° C. 100° C. T 5% 10% 50% Fomblin ® 4000 30 18 5.6 196 247 304 Z03 PFPE Product of 3700 — 82 10.3 209 255 341 ex. 3

Test 3—Evaluation of Surface Properties

A Q-panel® test panel was coated with a 30 μm film obtained by radical photopolymerization of the compound of example 9 in the presence of 5% (w/w) of 2,2-dimethoxy-2-phenylacetophenone as photoinitiator, using a UV light Fusion system model VPS 1600 equipped with a 13 mm H lamp.

The surface properties of the UV-cured film was then evaluated measuring the static contact angles vs water and vs n-hexadecane of the coated Q-Panel®; the results are reported in table 3 below.

Test 4

A Q-Panel® test panel was coated with a 30 μm film obtained by radical photopolymerization of a 75/25 (w/w) formulation of the compound of example 9 with trypropylene glycol diacrylate (TPGDA) in the presence of 5% (w/w) of 2,2-dimethoxy-2-phenylacetophenone as photoinitiator, using a UV light Fusion system model VPS 1600 equipped with a 13 mm H lamp.

The surface properties of the UV-cured film were then evaluated measuring the static contact angles vs water and vs n-hexadecane of the coated Q-panel test panel; the results are reported in table 3 below.

TABLE 3 Table 3 θ water θ n-hexadecane Al Q-panel ® test panel  89 ± 2 48 ± 2 Al Q-panel ® test panel treated 105 ± 1 57 ± 1 with the compound of example 9 Al Q-panel ® test panel treated 103 ± 1 56 ± 1 with the compound of example 9 and TPGDA (75/25) 

The invention claimed is:
 1. A process for the preparation of a (per)fluoropolyether block copolymer, the block copolymer comprising: A) a fluoropolyoxyalkylene segment (chain R_(a)) comprising one or more units of formula (CHXCF₂CF₂O)— in which X is hydrogen or fluorine; and B) a (per)fluoropolyoxyalkylene segment (chain R_(f)), wherein chain R_(f) complies with formula: —(CF₂CF₂O)_(p′)(CF₂O)_(q′)— wherein p′ and q′ are integers ≧0 and are selected in such a way that chain R_(f) has a molecular weight greater than 400 g/mol, said process comprising ring-opening a 2,2,3,3-tetrafluorooxethane with an acyl fluoride of a (per)fluoropolyether comprising chain R_(f) in the presence of an inorganic or organic fluoride.
 2. The process according to claim 1, wherein the (per)fluoropolyether block copolymer complies with formula (IA): R_(a)—R_(f)—R_(a′)  (IA) wherein chain R_(f) is as defined in claim 1 and chain R_(a) is selected from: a group (II) of formula: (CH₂CF₂CF₂O)_(n)CH₂CF₂C(O)F  (II) wherein n is an integer equal to or higher than 1; a group (III) of formula: (CH₂CF₂CF₂O)_(n)CH₂CF₂C(O)R  (III) wherein n is as defined above, and R is hydrogen a hydroxy group or a W—R¹ group in which W is a bond or is selected from —O—, —NH—, —OC(O)—, and —NHC(O)—; and R¹ is selected from: a straight or branched, saturated or unsaturated (C₁-C₃₆)hydrocarbon chain; a (C₅-C₁₄)cycloalkyl or (C₅-C₁₄)cycloalkyl(C₁-C₁₀)alkyl group, the cycloalkyl moiety being optionally substituted with one or more (C₁-C₄)straight or branched alkyl chains; a (C₆-C₁₄)aryl or (C₁-C₁₀)alkyl(C₆-C₁₄)aryl group; and a group of formula —R^(A)—CR_(H)═CH₂ in which R_(H) is hydrogen or a (C₁-C₃₄)straight or branched, saturated or unsaturated hydrocarbon chain and R^(A) is selected from: —NH—R^(B)—O—CO—;  (j) —NH—R^(B)—NHCOO—R^(B)—OCO—; and  (jj) —R^(B)—O—CO—;  (jjj) R^(B) being a divalent group selected from: a (C₁-C₁₀)aliphatic group, a (C₅-C₁₄)cycloaliphatic group, a (C₆-C₁₄)aromatic, or a (C₁-C₁₀)alkyl(C₆-C₁₄aryl) group; a group (IV) of formula: (CH₂CF₂CF₂O)_(n)CH₂CF₂CH₂OR′  (IV) wherein n is as defined above and R′ is hydrogen or a (CHR²CHR³O)_(m)—R⁴ group in which: R² and R³ are both hydrogen or one is hydrogen and the other is methyl; m is 0 or an integer equal to or higher than 1; R⁴ is selected from hydrogen, with the proviso that, when m is 0, R⁴ is not hydrogen; a straight or branched, saturated or unsaturated (C₁-C₃₆)hydrocarbon chain; a (C₅-C₁₄)cycloaliphatic or (C₁-C₁₀)alkyl(C₅-C₁₄)cycloalkyl group; a (C₆-C₁₄)aromatic or (C₁-C₁₀)alkyl(C₆-C₁₄)aromatic group; a P(O)R⁵R⁶ group, in which R⁵ and R⁶ are, independently of each other, selected from hydroxy and —O⁻X⁺ groups, in which X⁺ is selected from Li⁺, Na⁺, K⁺, (NH₃R′)⁺, (NH₂R′R″)⁺ and (NHR′R″R′″)⁺ wherein R is H or a linear or branched (C₁-C₂₂)alkyl group optionally containing one or more —OH groups, and R′, R″ and R″, equal to or different from each other, are linear or branched (C₁-C₂₂)alkyl groups optionally containing one or more —OH groups or optionally linked to each other to form N-heterocyclic groups; a COR⁷ group, in which R⁷ is selected from a straight or branched, saturated or unsaturated (C₁-C₃₆)hydrocarbon chain; a (C₅-C₁₄)cycloaliphatic or (C₁-C₁₀)alkyl(C₅-C₁₄)cycloalkyl group; a (C₆-C₁₄)aromatic or (C₁-C₁₀)alkyl(C₆-C₁₄)aromatic group; a CONHR⁸ group, in which R⁸ is the same as R⁷; a COR⁷ group, in which R⁷ is as defined above; and a CO—R^(A)—CR_(H)═CH₂ group, wherein R_(H) is hydrogen or a straight or branched, saturated or unsaturated (C₁-C₃₄)hydrocarbon chain and R^(A) is selected from: —NH—R^(B)—O—CO—;  (j) —NH—R^(B)—NHCOO—R^(B)—OCO—; and  (jj) —R^(B)—O—CO—;  (jjj) R^(B) being a divalent group selected from a (C₁-C₁₀)aliphatic group, a (C₅-C₁₄)cycloaliphatic group, a (C₆-C₁₄)aromatic group or a (C₁-C₁₀)aliphatic(C₆-C₁₄)aromatic group; a group (V) of formula: (CHYCF₂CF₂O)_(n)CHYCF₃  (V) wherein n is as defined above and Y is fluorine or hydrogen; and a group (VI) of formula: (CH₂CF₂CF₂O)_(n)CH₂CF₂H  (VI) wherein n is as defined above; and wherein R_(a′) is the same as R_(a) or is a (C₁-C₅)(per)fluoroalkyl group optionally containing hydrogen and/or chlorine atoms.
 3. The process according to claim 2, wherein R⁷ is selected from a —CR_(H)═CH₂ chain, wherein R_(H) is hydrogen or a straight or branched, saturated or unsaturated (C₁-C₃₄)hydrocarbon chain; a (C₅-C₁₄)cycloaliphatic or (C₁-C₁₀)alkyl(C₅-C₁₄)cycloalkyl group; and a (C₆-C₁₄)aromatic or (C₁-C₁₀)alkyl(C₆-C₁₄)aromatic group.
 4. The process according to claim 1, wherein the ratio of p/q is
 2. 